Lighting device having a multi-position switch assembly

Abstract

A switch assembly that may be utilized as a tail cap of a lighting device. The switch assembly including at least a depressible switch with a rotatable portion that allows the user to activate distinct functional modes of the lighting device. In an illustrative, non-limiting embodiment, the switch assembly has four channels, providing for at least three different light functions and a locking channel. The different channels are defined by the axial position of the rotatable portion relative to the lighting device body.

1. A lighting device having a multi-channel switch assembly, comprising:
 a head assembly, wherein the head assembly comprises a light source; 
 a light body having a first end and a second end, wherein the head assembly is coupled to a first end of the light body; 
 a battery housing, wherein an interior cavity of the battery housing defines a battery compartment capable of receiving a battery, and wherein the battery housing is positioned within a cavity formed by the light body; 
 an switch assembly coupled to a second end of the light body via a threaded collar, wherein the switch assembly is indexed to the light body, wherein the switch assembly comprises at least some of a rotator that is rotatable to at least one light activating channel relative to the light body; 
 an actuator, wherein the actuator includes a magnet coupled to a lower portion of the actuator such that the magnet is maintained in a fixed position relative to the actuator, and wherein the actuator is coupled to the rotator such that when the rotator is rotated to a light activating channel, the actuator and the magnet are also rotated to a corresponding light activating position, a button coupled to the actuator, and a switch cup rotatably coupled to the rotator and the threaded collar, wherein when the switch assembly is coupled to the light body, the switch cup is indexed to the light body, and wherein the switch cup is electrically coupled to a negative terminal of the battery such that, when the switch assembly is coupled to the light body, the switch cup is electrically coupled to the light body and the controller; 
 at least one Hall effect sensor associated with each light activating channel of the switch assembly, wherein each Hall effect sensor is capable of producing an activation signal when the magnetic field from the magnet activates the proximate Hall effect sensor; 
 wherein, when the button is depressed, the actuator is moved from a first position within the switch cup to a second position within the switch cup, such that the magnet is moved to a position that is proximate the Hall effect sensor associated with an instant light activating channel of the rotator such that the magnetic field of the magnet activates the proximate Hall effect sensor associated with an instant light activating channel of the rotator; and 
 a controller, wherein the controller is electrically coupled to each Hall effect sensor such that the controller is capable of receiving an activation signal from each Hall effect sensor and determining the output function for the light source that is represented by the activated Hall effect sensor, wherein the controller is electrically coupled to the light source and the battery such that the controller is capable of energizing the light source in response to the receipt of an activation signal from each Hall effect sensor and controlling the output patterns and on/off functions of the light source. 
 
     
     
       2. The lighting device of  claim 1 , wherein the light source comprises at least one light emitting diode that is capable of emitting visible or non-visible wavelength light. 
     
     
       3. The lighting device of  claim 1 , wherein the light source comprises at least one incandescent illumination device that is capable of emitting visible or non-visible wavelength light. 
     
     
       4. The lighting device of  claim 1 , wherein the light source comprises at least one light emitting diode and at least one incandescent illumination device, wherein the at least one light emitting diode and the at least one incandescent illumination device are capable of emitting visible or non-visible wavelength light. 
     
     
       5. The lighting device of  claim 1 , wherein the light source comprises a laser emitter, wherein the laser emitter is capable of emitting visible or non-visible wavelength light. 
     
     
       6. The lighting device of  claim 1 , wherein the controller is disposed between the battery housing and the light body. 
     
     
       7. The lighting device of  claim 1 , wherein the controller comprises an integrated circuit. 
     
     
       8. The lighting device of  claim 1 , wherein the controller comprises a high current MOSFET. 
     
     
       9. The lighting device of  claim 1 , wherein the controller is capable of being reprogrammed via a direct linked connection to a reprogramming device. 
     
     
       10. The lighting device of  claim 1 , wherein the controller is capable of being reprogrammed via an indirect connection to a reprogramming device. 
     
     
       11. The lighting device of  claim 1 , wherein the head assembly is permanently attached to the light body assembly. 
     
     
       12. The lighting device of  claim 1 , wherein the battery housing is permanently attached within the cavity formed by the light body. 
     
     
       13. The lighting device of  claim 1 , wherein each Hall effect sensor is coupled to the battery housing. 
     
     
       14. The lighting device of  claim 1 , wherein each Hall effect sensor is coupled to a portion of the light body. 
     
     
       15. The lighting device of  claim 1 , wherein each Hall effect sensor is electrically coupled to the controller via a flexible circuit, which is included between the battery housing and the light body. 
     
     
       16. The lighting device of  claim 1 , wherein the button return spring is positioned so as to provide a measure of return force to the button. 
     
     
       17. The lighting device of  claim 1 , wherein the switch assembly includes a locking channel, wherein the locking channel prevents the actuator from moving to the second position. 
     
     
       18. The lighting device of  claim 1 , wherein the switch assembly includes a locking channel, wherein the locking channel does not include an associated Hall effect sensor. 
     
     
       19. The lighting device of  claim 1 , wherein the interior of the switch cup is not sealed relative to the outside environment, such that the interior of the switch cup is maintained at a same pressure as an outside of the switch assembly. 
     
     
       20. The lighting device of  claim 1 , wherein the light activating channels include a strobe mode channel, a constant on and adjustable mode channel, and a momentary maximum power on mode channel. 
     
     
       21. The lighting device of  claim 20 , wherein in the strobe mode the light source is controlled to illuminate at maximum power then off at a rate of greater than 0 to 60 Hz when the button is depressed. 
     
     
       22. The lighting device of  claim 20 , wherein in the strobe mode the light source is controlled to illuminate at maximum power then off at a rate of greater than 0 to 30 Hz when the button is depressed. 
     
     
       23. The lighting device of  claim 20 , wherein in the strobe mode the light source is controlled to illuminate at maximum power then off at a rate of about 8 to 20 Hz when the button is depressed. 
     
     
       24. The lighting device of  claim 20 , wherein in the constant on and adjustable mode the light source illuminated at a predetermined light level when the button is depressed fully and released relatively quickly and wherein the light source is turned off when the button is again depressed fully and released relatively quickly. 
     
     
       25. The lighting device of  claim 20 , wherein in the constant on and adjustable mode the light source is controlled by the controller to illuminated at a predetermined light level and then initiate a dimming and brightening cycle when the button is depressed and maintained in a depressed state for a determined period of time, and wherein if the button is released at any point during the dimming and brightening cycle, the light source is controlled to remain at the brightness level the light source was at when the button was released. 
     
     
       26. The lighting device of  claim 25 , wherein in the constant on and adjustable mode the light source is controlled by the controller to initiate a dimming and brightening cycle beginning from the brightness level the light source was at when the button was released when the button is once again maintained in a depressed state for a determined period of time. 
     
     
       27. The lighting device of  claim 25 , wherein in the constant on and adjustable mode, when the button is depressed and released relatively quickly, the light source is controlled by the controller to turn off. 
     
     
       28. The lighting device of  claim 1 , wherein the light activating channels include a signaling mode channel. 
     
     
       29. The lighting device of  claim 28 , wherein in the signaling mode a visible light source is controlled to illuminate at a predetermined pattern when activated. 
     
     
       30. The lighting device of  claim 29 , wherein in the signaling mode a visible light source is controlled to illuminate at a user programmable pattern when activated. 
     
     
       31. The lighting device of  claim 28 , wherein in the signaling mode a non-visible light source is controlled to illuminate at a predetermined pattern when activated. 
     
     
       32. The lighting device of  claim 31 , wherein in the signaling mode a non-visible light source is controlled to illuminate at a user programmable pattern when activated. 
     
     
       33. The lighting device of  claim 1 , wherein at least one of the head assembly, the light body, the battery housing, the switch assembly, the threaded collar, the rotator, the actuator, or the button comprises steel, aluminum, titanium, and/or other ferros or non-ferros metals, alloys and composites thereof, glass-hardened polymers, polymer or fiber reinforced metals, carbon fiber or glass fiber composites, thermoset or thermoplastic resins, chopped glass or carbon fibers used for injection molding compounds, laminate glass or carbon fiber, epoxy laminates, woven glass fiber laminates, impregnate fibers, polyester resins, epoxy resins, phenolic resins, polyimide resins, cyanate resins, high-strength plastics, polymers, polymeric composites, thermoplastics, polypropylene, nylon, glass, or polymer fiber reinforced plastics, thermoform and/or thermoset sheet materials, and/or various combinations of the foregoing. 
     
     
       34. The lighting device of  claim 1 , wherein the threaded collar includes a plurality of lugs that extend substantially radially from the threaded collar. 
     
     
       35. The lighting device of  claim 1 , wherein the at least a portion of the light body has about a 1 inch outer diameter. 
     
     
       36. The lighting device of  claim 1 , wherein the head assembly includes a bezel portion and wherein at least a portion of the bezel has about a 1¼ inch outer diameter. 
     
     
       37. A lighting device having a multi-channel switch assembly, comprising:
 a head assembly, wherein the head assembly comprises a light source; 
 a light body having a first end and a second end, wherein the head assembly is coupled to a first end of the light body; 
 a battery housing, wherein an interior cavity of the battery housing defines a battery compartment capable of receiving a battery, and wherein the battery housing is positioned within a cavity formed by the light body; 
 an switch assembly coupled to a second end of the light body via a threaded collar, wherein the switch assembly comprises at least some of a rotator that is rotatable to at least two light activating channels relative to the light body; 
 an actuator, wherein the actuator includes a first electrical contact coupled to a lower portion of the actuator such that the first electrical contact is maintained in a fixed position relative to the actuator, and wherein the actuator is coupled to the rotator such that when the rotator is rotated to a light activating channel, the actuator and the first electrical contact are also rotated to a corresponding light activating channel; 
 a button coupled to the actuator; 
 a switch cup rotatably coupled to the rotator and the threaded collar, wherein when the switch assembly is coupled to the light body, the switch cup is indexed to the light body, and wherein the switch cup is electrically coupled to the battery such that, when the switch assembly is coupled to the light body, the switch cup is electrically coupled to the light body and the controller; 
 at least one second electrical contact associated with each light activating channel of the switch assembly, wherein each second electrical contact is capable of producing an activation signal when the first electrical contact makes electrical contact with the second electrical contact; 
 wherein, when the button is depressed, the actuator is moved from a first position within the switch cup to a second position within the switch cup, such that the first electrical contact is moved to a position wherein the first electrical contact makes electrical contact with the second electrical contact associated with an instant light activating channel of the rotator such that the electrical contact of the first electrical contact activates the proximate second electrical contact associated with an instant light activating channel of the rotator; and 
 a controller, wherein the controller is electrically coupled to each second electrical contact such that the controller is capable of receiving an activation signal from each second electrical contact and determining the output function for the light source that is represented by the activated second electrical contact, wherein the controller is electrically coupled to the light source and the battery such that the controller is capable of energizing the light source in response to the receipt of an activation signal from each second electrical contact and controlling the output patterns and on/off functions of the light source. 
 
     
     
       38. The lighting device of  claim 37 , wherein the first electrical contact travels in an aperture formed in the switch cup.